System and method for a practical synthetic fiber tension member to rod connection

ABSTRACT

A method and system for creating a hybrid tensile member combining a synthetic fiber cable and a rigid rod. An anchor is attached to one or more ends of the synthetic cable. The anchor is used to connect an end of the fiber cable to a length of conventional rod, preferably through the use of a swaging operation. Each rod segment includes a standard end feature on its free end—such as a threaded shaft or J-bend. The hybrid assembly can preferably be retrofitted to applications that now use a conventional rod.

CROSS-REFERENCES TO RELATED APPLICATIONS

This non-provisional patent application claims priority to ProvisionalApplication Ser. No. 63/218,592. The provisional application listed thesame inventor as the present application.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

MICROFICHE APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates to the field of tensile strength members. Morespecifically, the invention comprises a method for connecting a flexiblesynthetic fiber rope or cable tension member to one or more rigid rodtension members.

2. Description of the Related Art

A rod—whether made of metal, an organic material, or a compositematerial—is an efficient tensile strength member. Rods are simple. Rodsare very compact. Rods can be provided with a wide variety of endconnecting features—such as threads, an expanded lug, a loading eye,etc. Steel is a very common material for prior art tensile strengthrods. It is also known to make tensile strength rods using pultrudedcarbon fiber, glass fiber, or other materials.

The present invention proposes to substitute a flexible cable made ofsynthetic filaments for a portion of the length of a conventionalrod—thereby producing a hybrid construction. The present invention alsoseeks to retain the use of standard end fittings for the hybridconstruction. Each field of application will have its own standard endfittings and its own space constraints for an attempted retrofit. Theinvention is adaptable to many diverse fields of application.

The creation of a hybrid assembly has advantages over the prior artunitary construction in many respects. However, the space efficiency ofa conventional rod likely cannot be surpassed. The creation of a jointbetween a flexible cable and a prior art rod segment produces anenlarged segment in the region of the joint. The present invention seeksto minimize the enlargement so that the hybrid assembly can besubstituted for existing unitary constructions.

A well-known application for tensile strength rods is in theconstruction of spoked wheels. As an example, bicycle wheels are oftenmade by “lacing” a number of rods between a central hub and an outerrim. The rods in this context are known as “spokes.” Bicycle wheels arean obvious application for the present invention. Accordingly, many ofthe exemplary illustrations pertain to bicycle wheels. The reader shouldbear in mind, however, that the invention has many other applicationsand that the scope of the invention is by no means limited to spokedwheels.

FIG. 1 shows a partial elevation view of a bicycle wheel—the structureof which will be familiar to those skilled in the art. Flange 28 isattached to the wheel's hub and may in fact be integral to the hub. Rim18—which is shown in section—forms the wheel's perimeter. The tire andtube are not shown for purposes of visual clarity, but these additionalcomponents attach to rim 18.

Spoke 10 is one of a set of spokes that are laced between flange 28 andrim 18. It is common to use 24 to 36 spokes to lace a wheel. Thoseskilled in the art will know that many different fastening componentsare used in wheel lacing. FIG. 1 shows a common and representative priorart configuration. The inner portion of each spoke 10 is connected toflange 28 by passing the spoke—starting with threaded end 16—through atransverse hole in flange 28. Expanded head 14 is too large to passthrough this transverse hole and it arrests further passage of thespoke. The final position is as shown. J-bend 12 provides anapproximately 90-degree bend so that spoke 10 has the correctorientation.

Nipple 20 is pressed inward through passage 24. Head 22 stops furtherinward movement of the nipple once head 22 comes to rest against grommet26. In this example grommet 26 is a steel piece that is plasticallydeformed in order to lock it to rim 18—which is made of a lighter alloy.In other known arrangements the grommet will simply be integral to therim itself.

Nipple 20 has a female threaded passage configured to engage threadedportion 16 on the outer end of the spoke. The nipple also has two ormore wrench flats that can be easily engaged to turn the nipple. Aperson building a wheel “laces” all the spokes and all the nipples intoposition before beginning to adjust the spoke tension. Once the nipplesare threaded onto the ends of the spokes the reader will appreciate thatturning the nipples will adjust the tension applied to the spokes.

Rod tensile members are inherently compact, and this is one of theirmain advantages. FIG. 2 provides an elevation view of a bicycle wheel inthe vicinity of hub 30. The reader will note that the spokes do notsimply radiate outward in a direction that is perpendicular to anintersection with the tangent point on the rim. Rather, the spokes 10are deliberately crossed over each other in offset directions. There aremany known lacing configurations. The one shown in FIG. 2 is a“two-cross” arrangement. The reader will note how each spoke crosses afirst additional spoke at first crossing point 34 and a secondadditional spoke at second crossing point 36. The spokes shown aresecured to flange 28 using J-bends. The reader will observe how theorientation of each J-bend is reversed with respect to its neighbors. Onone spoke the view of FIG. 2 allows only the view of a J-bend goingthrough a hole 32 in flange 28. For the two adjacent spokes the view ofthe hole is blocked by a head 14.

The interrelationship of the spokes is complex. The view of FIG. 2 showsonly the driveside flange 28—the side where the chain engages the gears.Hub 30 includes a second flange (the non-driveside flange) as well, andthis second flange hosts the same number of connected spokes. Thenumerous spoke crossing points and overlapping geometry means that abulky hybrid assembly cannot be substituted for the slender spokes. Anysubstitute assembly configured to replace the classic bicycle spoke islimited by these significant space constraints. Additionally, anychanges in the geometry of the end points means that conventional hubsand rims cannot be used.

Another factor in attempting to create the inventive hybrid assembly isthe need to use numerous standard end features common to spoked wheels.FIG. 3 depicts a small sample of these standard end features. The upperspoke includes a male-threaded end, with female-threaded nipple 20installed on that end. The middle spoke 10 includes J-bend 12 withincorporated head 14. The lower spoke (sometimes called a“straight-pull” spoke) incorporates an expanded head 14 on its end. Manyother end fittings exist in the field of bicycle wheels. Of course,other fields have many more and diverse types of standard end features.

In the present invention a flexible cable made of high-strengthsynthetic filaments must generally be connected to a conventional rodmade of metal or non-metallic materials. The term “cable” should beunderstood to encompass any flexible tensile strength member, includingcables, ropes, cords, strands, tendons, etc. The term “cable” should notbe understood to encompass rigid structures. To make the hybrid cableand rod assembly, an anchor is preferably affixed to each end of thecable. The anchor can be affixed by mechanical means—such as acone-and-spike socket, clamping around a thimble, weaving a cable arounda cross pin and back into itself, etc. The anchor can also be affixed tothe cable by potting. In a potting process, a length of strands isplaced within a cavity in the anchor and liquid potting compound isintroduced around and within the strands in the cavity (either before,during, or after the strands are placed in the cavity). The term“potting compound” as used in this description means any substance whichtransitions from a liquid to a solid over time. Examples include moltenlead, thermoplastics, and UV-cure or thermoset resins (such as two-partpolyesters or epoxies). Other examples include plasters, ceramics, andcements. The term “solid” is by no means limited to an orderedcrystalline structure such as found in most metals. In the context ofthis invention, the term “solid” means a state in which the materialdoes not flow significantly under the influence of gravity. Thus, a softbut stable wax is yet another example of such a solid. Once the pottingcompound is solidified, the anchor is attached to the end of the cable.Many known approaches to adding an anchor to a cable are explained indetail in commonly-owned U.S. Pat. Nos. 7,237,336; 8,048,357; 8,236,219;8,371,015; and 10,543,573—all of which are hereby incorporated byreference.

Many different synthetic filaments (sometimes synonymously referred toas “fibers”) are used for creating the type of cables that can beincorporated in the hybrid assemblies of the present invention. Theseinclude DYNEEMA (ultra-high-molecular-weight polyethylene), SPECTRA(ultra-high-molecular-weight polyethylene), TECHNORA (aramid), TWARON(p-phenylene terephthalamide), KEVLAR (para-aramid synthetic fiber),VECTRAN (a fiber spun from liquid-crystal polymer), PBO(poly(p-phenylene-2,6-benzobisoxazole)), carbon fiber, and glass fiber(among many others). In general, the individual filaments have athickness that is less than that of human hair.

Those skilled in the art will know that cables made from syntheticfilaments have a wide variety of constructions. Some cables have aparallel core of filaments surrounded by a jacket of braided filaments.In other cases the cable may be braided throughout. In still otherexamples the cable construction may be: (1) an entirely parallelconstruction enclosed in a jacket made of different material, (2) ahelical “twist” construction, or (3) a more complex construction ofmultiple helices, multiple braids, or some combination of helices andbraids.

The term “anchor” should be viewed broadly to encompass virtuallyanything that can be attached to a flexible rope or cable. A singleanchor may be attached to the entire cable. In other cases an anchor maybe attached to each strand (or other subgroup) of a cable so that asingle end of a cable has multiple anchors. These multiple anchors arethen typically gathered together by one or more additional componentscalled collectors. An anchor ordinarily includes some feature orfeatures facilitating attachment—such as a flange, square end, hook, ora threaded shaft.

In many instances the substitution of a cable with synthetic filamentsoffers an advantage in performance—such as improved shock and fatigueresistance, improved dampening (by introducing the viscoelasticproperties of the synthetic cable), an improvedstrength-to-weight-ratio, or improved dampening. In some applicationsthe present invention may be desirable because it actually offers lessstiffness and different viscoelastic properties. This is particularlytrue for a hybrid assembly configured to substitute for a conventionalsteel bicycle spoke. The use of certain synthetic filaments in a hybridspoke assembly produces a smoother ride for a bicyclist. This is theresult of the unique viscoelastic properties of certain filaments, aswill be explained in the detailed disclosure. The inclusion of a longeror shorter portion of synthetic cable within the overall length of thespoke can actually serve to “tune” the mechanical properties of thehybrid assembly in order to produce desired properties.

The present invention seeks to exploit the advantageous properties ofhybrid tensile members, while retaining the ability to use standardizedend features. In order to do so, the invention must overcome severaldisadvantages inherent in the components being used. One objective isfor all the components in the hybrid assembly to retain the overallbreaking strength of the rod segment alone. Under this scheme, it iscommon for the flexible cable's diameter to be 1.5 to 3.0 times thediameter of the rod. In addition, the anchor that is commonly potted tothe end of the flexible cable often has a diameter that is 2.0 to 3.0times the diameter of the cable. Thus, the overall anchor diameter maybe 3.0 to 9.0 times the diameter of the rod. This fact makes theconnection between the cable and the rod significantly bulkier than therod itself. An objective of the present invention is minimizing the bulkof this connection. Another objective is placing the bulk in a regionwhere space is available. Additional objectives include (1) the abilityto retrofit the hybrid assembly into prior art unitary constructionapplications, (2) the ability to provide mechanical characteristics notavailable with the prior art unitary construction, and (3) the abilityfor the connection to meet or exceed the strength of the rod itself.These and other objects and advantages are explained in the detaileddescription to follow.

BRIEF SUMMARY OF THE PRESENT INVENTION

The present invention comprises a method and system for creating ahybrid tensile member combining a synthetic fiber cable and a rigid rod.An anchor is attached to one or more ends of the synthetic cable. Theanchor is used to connect an end of the fiber cable to a length ofconventional rod, preferably through the use of a swaging operation.Each rod segment includes a standard end feature on its free end—such asa threaded shaft or J-bend. The hybrid assembly can preferably beretrofitted to applications that now use a conventional rod or wire.This allows synthetic fiber cables—with their unique mechanicalproperties—to be incorporated in existing designs.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an elevation view with a partial section, showing a prior artspoked bicycle wheel assembly.

FIG. 2 is a detailed elevation view, showing a prior art bicycle wheelassembly.

FIG. 3 is a perspective view, showing three standard end features forbicycle wheel spokes.

FIG. 4 is a perspective view, showing exemplary embodiments of theinventive hybrid tensile member assemblies with three standard endfeatures for bicycle wheel spokes.

FIG. 5 is a sectional elevation view, showing an anchor connected to anend of a synthetic cable—prior to a swaging operation used to connectthe anchor to a rod.

FIG. 6 is a sectional elevation view, showing the anchor of FIG. 5 ,with a rod end inserted prior to swaging.

FIG. 7 is a sectional elevation view, showing the assembly of FIG. 6after swaging.

FIG. 8 is a sectional elevation view, showing a rod end with threeadditional circumferential ribs having a triangular profile.

FIG. 9 is a sectional elevation view, showing the assembly of FIG. 8after swaging.

FIG. 10 is a sectional elevation view, showing a rod end with anenlarged end portion.

FIG. 11 is a sectional elevation view, showing the assembly of FIG. 10after swaging.

FIG. 12 is an elevation view, showing a rod end with three ribs having asquare profile.

FIG. 13 is an elevation view, showing a rod end having an expandedportion with a tapered profile.

FIG. 14 is an elevation view, showing a rod end having an enlargeddiameter proximate its end.

FIG. 15 is an elevation view, showing a rod end having a helical groove.

FIG. 16 is an elevation view, showing a rod end having a threadedportion.

FIG. 17 is a sectional elevation view, showing an anchor having avarying wall profile and a rod end.

FIG. 18 is a sectional elevation view, showing the assembly of FIG. 17after swaging.

FIG. 19 is a sectional elevation view, showing an anchor having avarying wall profile and a rod end.

FIG. 20 is a sectional elevation view, showing the assembly of FIG. 19after swaging.

FIG. 21 is a sectional elevation view, showing an anchor having avarying wall profile and a rod end.

FIG. 22 is a sectional elevation view, showing the assembly of FIG. 21after swaging.

FIG. 23 is a sectional elevation view, showing an anchor and a rod endhaving an enlarged end portion.

FIG. 24 is a sectional elevation view, showing a first step in theswaging of the assembly of FIG. 23 .

FIG. 25 is a sectional elevation view, showing a second step in theswaging of the assembly of FIG. 23 .

FIG. 26 is a sectional elevation view, showing an assembly of an anchorhaving internal ribs and a rod end.

FIG. 27 is a sectional elevation view, showing the assembly of FIG. 26after swaging.

FIG. 28 is a sectional elevation view, showing an anchor, a coupler, anda rod end.

FIG. 29 is a sectional elevation view, showing a first step in theswaging of the assembly of FIG. 28 .

FIG. 30 is a sectional elevation view, showing a second step in theswaging of the assembly of FIG. 28 .

FIG. 31 is a sectional elevation view, showing a threaded anchor, athreaded coupler, and a rod end.

FIG. 32 is a sectional elevation view, showing the assembly of FIG. 31after swaging.

FIG. 33A is an elevation view, showing a swaged assembly and alternaterod end features.

FIG. 33B is an elevation view, showing a threaded rod segment.

FIG. 33C is an elevation view, showing a rod segment with an eye.

FIG. 33D is an elevation view, showing a rod segment with a cross piece.

FIG. 33E is an elevation view, showing a rod segment with a J-bend and ahead.

FIG. 34A is an elevation view, showing a rod segment with a taperedexpansion.

FIG. 34B is an elevation view, showing a rod segment with an expandedhead.

FIG. 34C is an elevation view, showing a rod segment with a yoke.

FIG. 34D is an elevation view, showing a cylindrical rod segment.

FIG. 35A is a sectional elevation view, showing an alternate swagingprofile.

FIG. 35B is a sectional view, showing a circular swage.

FIG. 36C is a sectional view, showing a square swage.

FIG. 35D is a sectional view, showing an octagonal swage.

FIG. 35E is a sectional view, showing a cruciform swage.

FIG. 35F is a sectional view, showing a convoluted swage.

FIG. 36 is a sectional elevation view, showing the use of a removableinternal tool for the swaging operation.

FIG. 37 is a sectional elevation view, showing a swaged anchor afterthreading.

FIG. 38 is a sectional elevation view, showing a swaged anchor afterthreading with the addition of a threaded rod end.

FIG. 39 is a sectional elevation view, showing the use of an insert aspart of the swaged interface.

FIG. 40 is a sectional elevation view, showing the assembly of FIG. 39after swaging.

FIG. 41 is a sectional elevation view, showing the use of a threadedinsert as part of the swaged interface.

FIG. 42 is a sectional elevation view, showing the assembly of FIG. 41after swaging.

FIG. 43A is a sectional elevation view, showing a swaging insert.

FIG. 43B is a sectional elevation view, showing a swaging insert.

FIG. 43C is a sectional elevation view, showing a swaging insert.

FIG. 43D is a sectional elevation view, showing a swaging insert.

FIG. 43E is a sectional elevation view, showing a swaging insert.

FIG. 44A is a sectional elevation view, showing a swaging insert.

FIG. 44B is a sectional elevation view, showing a swaging insert.

FIG. 44C is a sectional elevation view, showing a swaging insert.

FIG. 44D is a sectional elevation view, showing a swaging insert.

FIG. 45A is a sectional elevation view, showing a rod end attachment.

FIG. 45B is a sectional elevation view, showing a rod end attachment.

FIG. 45C is a sectional elevation view, showing a rod end attachment.

FIG. 45D is a sectional elevation view, showing a rod end attachment.

FIG. 46 is a sectional elevation view, showing an anchor incorporating atransverse bulkhead.

FIG. 47 is a sectional elevation view, showing the assembly of FIG. 46after swaging.

FIG. 48 is a sectional elevation view, showing the use of a swagedconnection to connect to a wire rope.

FIG. 49 is a sectional elevation view, showing the assembly of FIG. 48after swaging.

FIG. 50 is a sectional elevation view, showing the use of a swagingcoupler having a transverse bulkhead.

FIG. 51 is a stress versus strain plot.

REFERENCE NUMERALS IN THE DRAWINGS

-   -   10 spoke    -   12 J-bend    -   14 head    -   16 threaded portion    -   18 rim    -   20 nipple    -   22 head    -   24 passage    -   26 grommet    -   28 flange    -   30 hub    -   32 hole    -   34 first crossing point    -   36 second crossing point    -   38 synthetic cable    -   40 anchor    -   41 potting cavity    -   42 rod segment    -   43 throat    -   44 rod end    -   46 jacket    -   48 potted region    -   50 potting transition    -   52 extended distal wall    -   54 cavity    -   56 opening    -   58 swaged interface    -   60 pointed rib    -   62 expanded portion    -   64 tapered portion    -   65 square rib    -   66 conical end portion    -   68 head    -   70 fillet    -   72 helical groove    -   74 thread    -   76 thickened wall section    -   78 expanded portion    -   80 neck portion    -   82 expanding entrance portion    -   84 first stage swage    -   86 second stage swage    -   88 rib    -   90 plastically deformed indentation    -   92 plastically deformed rib    -   94 coupler    -   96 extended proximal wall    -   98 first swaged interface    -   100 second swaged interface    -   102 male thread    -   104 female thread    -   106 coupler    -   108 passage    -   110 eye    -   112 cross piece    -   114 tapered expansion    -   116 yoke    -   118 pin    -   120 distal cylinder    -   122 circular swage    -   124 square swage    -   126 octagonal swage    -   128 cruciform swage    -   130 convoluted swage    -   132 internal swaging die    -   134 female thread    -   136 annular pocket    -   138 insert    -   140 protrusion    -   142 passage    -   144 insert    -   146 male thread    -   148 female thread    -   149 insert    -   150 insert    -   151 insert    -   152 insert    -   154 insert    -   156 insert    -   158 insert    -   160 insert    -   162 insert    -   164 annular relief    -   166 rod end attachment    -   168 rod end attachment    -   170 rod end attachment    -   172 rod end attachment    -   174 threaded engagement    -   176 rod end attachment    -   178 bulkhead    -   180 vent    -   182 wire rope    -   184 end fitting    -   186 coupler    -   188 steel stress-strain curve    -   190 synthetic loading curve    -   192 synthetic unloading curve

DETAILED DESCRIPTION OF THE INVENTION

The basic concept of the present invention is to create a hybridassembly including a flexible synthetic cable and one or more rodsegments—wherein each rod segment has a standard end feature. In manyexamples a rod segment will be connected to both ends of the syntheticcable. This allows a synthetic cable to be retrofitted in manyapplications employing the standard end features. FIG. 4 shows threeexemplary embodiments. In each of these, anchor 40 is used to connect asynthetic cable 38 to a rod segment 42. The rod segments include astandard end feature for load transfer—such as a threaded shaftconnected to nipple 20, a J-bend 12 with expanded head 14, or a straightstem with expanded head 14.

FIGS. 5-7 illustrate a first example of connecting the rod segment to asynthetic cable 38 which serves well to illustrate the challenges facingthe present invention. Anchor 40 in this example is a radially symmetricmetal piece, having a proximal region on the side of cable 38 (proximatethroat 43) and a distal region on the opposite side (proximate opening56). In the context of this disclosure, the proximal direction shallmean moving in the direction from opening 56 toward throat 43 and thedistal direction shall mean moving in the direction from throat 43toward opening 56. The proximal region of the anchor includes pottingcavity 41. Cable 38 contains a large number of synthetic filaments(sometimes synonymously called fibers). These are usually containedwithin a surrounding polymer jacket 46. In this example, a length of thejacket is stripped away to reveal the filaments. The revealed length offilaments is placed within the potting cavity and splayed apart. Thislength is infused with liquid potting compound (before, during, or afterbeing placed within the potting cavity) and maintained within thepotting cavity as the potting compound transitions from a liquid to asolid. Once the potting compound has solidified, potted region 48 is acomposite of synthetic filaments and potting compound. The expandingnature of the potting cavity mechanically locks the cable to the anchor,since potted region 48 is too large to pass through throat 43. Pottingtransition 50 is the transition region between the potted region—wherethe filaments are locked within the solidified potting compound—and thefreely flexing portion of the cable. The potting transition is usuallyplaced inside the anchor—though this need not always be the case.

As shown in FIG. 5 , extended distal wall extends away from the pottingcavity in the distal direction. Cavity 54 is located within thesurrounding extended distal wall. Opening 56 leads from the exterior ofthe anchor to cavity 54. Rod end 44 is an end of the rod segment that isto be attached to the anchor. Rod end 44 is placed within cavity 54, asshown in FIG. 6 . A swaging operation is then performed in order toplastically deform extended distal wall 54 inward against rod end 44.FIG. 7 shows the assembly after the swaging operation. The extendeddistal wall has been plastically deformed inward against rod end 44 tocreate swaged interface 58.

Swaging can assume many forms. In the example shown in FIG. 6 , theswaging operation uses two dies squeezing inward as shown by the arrows.The swaging operation is repeated numerous times, with the swagingtool(s) being rotationally indexed about the anchor's central axis. Inthe result of FIG. 7 , the reader will note that the extended distalwall has been thinned and elongated, in addition to being deformedinward (a common result of a swaging operation). The result is a verytight frictional fit between the inward-facing surfaces of extendeddistal wall 52 and the outward facing surfaces of rod end 44—along thelength of swaged interface 58.

As those skilled in the art will know, swaged interface 58 can be madequite strong. The assembly thus created is subjected to tensile forcesparallel to the central axis shown. These forces tend to pull the rodend free of the anchor. However, the swaged interface created is strongenough to withstand very large tensile forces. The swaged interface isdesigned to withstand far more pulling force than the assembly will besubjected to in service.

In looking at FIG. 5 , the reader will readily appreciate that rod end44 has a smaller diameter than cable 38, and that cable 38 has a smallerdiameter than anchor 40. Potting cavity 41 must expand when proceedingin the distal direction within the anchor in order to create the desiredmechanical interference when the potting process is complete. Thisexpansion means that the overall diameter of the anchor must besignificantly more than the diameter of the cable itself. Minimizingthis overall diameter is an objective of the present invention. However,it is common for the cable to be 1.5 to 3.0 times the diameter of therod end, and it is common for the anchor to be 2.0 to 3.0 times thediameter of the cable.

The differing diameters for the rod end and the anchor create challengesfor the swaging process. The reader will note in FIG. 5 that rod end 44is much smaller than opening 56 and cavity 54. Opening 56 and cavity 54must generally be about the same diameter as the distal end of pottingcavity 41. This fact means that the swaging operation must plasticallydeform extended distal wall 52 a considerable distance inward. FIG. 7illustrates how far inward the deformation needs to be in order tocreate the desired swaged interface.

However, it is also important that the inward swaging forces notsubstantially deform anchor 40 in the vicinity of potted region 48.Inward deformation in this region can fracture the potted region48—thereby significantly reducing the strength of the potted connectionbetween the anchor and the cable. In order to avoid this phenomenon, theswaging operation is moved away from potted region 48 in the distaldirection. The reader will note in FIG. 7 how swaged interface 58 isdistal to the potted region. A suitable distal offset is provided inorder to avoid damaging the potted region.

Swaging has many advantages in the creation of a mechanical connection.It is generally (1) inexpensive, (2) compact, (3) has no movingcomponents, (4) has good fatigue resistance in tension, (5) adds noparts, and (6) is highly repeatable (consistent). Preferably thestrength of the swaged interface is made equal to the break strength ofthe rod segment itself. In order to accomplish this objective, it isoften desirable to provide grip-enhancing features within the swagedinterface. Many different features can be added to the rod end and/oranchor to increase the strength of the swaged interface. FIGS. 8-9 showsa first example of this. Three pointed circumferential ribs 60 are addedto rod end 44. FIG. 9 shows this assembly after rod end 44 has beenplaced in cavity 54 and a swaging operation carried out to create swagedinterface 58. The reader will note how the material of extended distalwall 52 has been plastically deformed around pointed ribs 60. Thisdeformation creates a mechanical interference in addition to frictionalengagement in the swaged interface—resulting in a greater ultimatetensile strength. Many other alternative grip-enhancing features may besubstituted.

Material selection for the components going into the swaged interfacecan be significant, and this is true for the example of FIGS. 8 and 9 .Rod end 44 is made of steel, whereas anchor 40 is made of aluminum inthis instance. An aluminum alloy is selected that can undergo plasticdeformation without work hardening to the point of embrittlement. Thealuminum alloy selected is able to deform to encompass the pointed ribsas shown in FIG. 9 .

FIGS. 10 and 11 show a second type of exemplary feature added to rod end44. The rod end includes expanded portion 62 and tapered portion 64. Thetapered portion links the expanded portion to the normal diameter forthe rod end. The expanded portion is placed within cavity 54 withinanchor 40, and the swaging operation is then carried out. FIG. 11 showsthe result. Extended distal wall 52 has been swaged inward to createswaged interface 58. A portion of the swaged interface lies over taperedportion 64—creating another mechanical interference in addition to thegripping force produced by the parallel surfaces within the swagedinterface.

FIGS. 12-16 illustrate additional gripping features that can be added torod end 44. FIG. 12 shows a rod end with the additional of three squareribs 65. FIG. 13 shows a rod end with the addition of conical endportion 66. FIG. 14 shows a rod end with the addition of an expandedhead 68. Fillet 70 joins the expanded head to the normal rod enddiameter.

FIG. 15 shows a rod end with the addition of helical grove 72. FIG. 16shows a rod end with the additional of a threaded portion 74. Thoseskilled in the art will realize that all these additional features areconfigured to add grip in the swaged interface. The grip-enhancingfeatures can take on countless diverse shapes.

FIGS. 17-22 illustrate exemplary features that can be added to extendeddistal wall 52 to vary the properties of the swaged interface. In theexample of FIG. 17 , the extended distal wall is provided with thickenedwall section 76. This is particularly useful where the anchor is made ofa ductile material—such as aluminum. The thickened wall section providesmore material for deformation during the swaging process, as well as thepotential for a stronger swaged interface. FIG. 18 shows thisconfiguration after swaging. Swaged interface 58 includes a thicker wallsection and enhanced strength. Additional swaging can beperformed—relative to the state shown in FIG. 18 —to extend the lengthof the swaged interface and thin the wall section in contact.

FIG. 19 shows another embodiment where neck portion 80 of the extendeddistal wall has a thicker section and expanded portion 78 does not. Thisconfiguration concentrates the force applied against rod end 44 duringthe swaging process—the force being concentrated at neck portion 80.Depending on the amount of swaging force used, this can plasticallydeform a portion of the rod end in addition to the extended distal wall.

FIG. 21 shows an example where the extended distal wall is provided withan expanded portion 78, a neck portion 80, and an expanded entrance 82.In this example the anchor is made of a harder material. FIG. 22 showsthe assembly after the swaging process. Neck portion 80 has been swagedlaterally into the rod end material and has actually plasticallydeformed rod end 44 as shown. Swaged interface 58 therefore contains amechanical interference as well as the frictional surface contact.

FIG. 23 shows an example using a rod end 44 having an expanded head 68.Expanded head 68 is placed within the cavity inside extended distal wall52. FIG. 24 shows the result of a first swaging operation in which firststage swage 84 deforms the extended distal wall inward against theperimeter of expanded head 68. FIG. 25 shows the result of a secondswaging operation in which second stage swage deforms the free end ofthe extended distal wall over the distal side of head 68 in order tocreate a significant mechanical interference in the joint. FIGS. 23-25illustrate the advantages of multiple swaging operations in someinstances. Two different sets of swaging dies can be used for theseoperations.

FIG. 26 shows an exemplary anchor 40 where ribs 88 have been added tothe inward facing wall of extended distal wall 52. FIG. 27 shows theresult of a swaging operation. In this case the anchor and the rod endare made of comparable materials. Plastic deformation of both theextended distal wall and the rod end results in this case. Ribs 88 arereduced in size and thickness—resulting in plastically deformed ribs 92.The previously smooth exterior of rod end 44 is likewise deformed intoplastically deformed indentations 90. A mechanical interference betweenthe ribs and the indentations—each of which have been work hardened—isthereby created in swaged interface 58.

In some embodiments the anchor can be made in multiple pieces. FIGS.28-32 illustrate this option. FIG. 28 shows an anchor 40 attached tocable 38 (In this example the attachment is made by potting). Thisparticular anchor does not have an extended distal wall. Instead, theextended distal wall is provided on coupler 94. The coupler 94 slidesover anchor 40. Extended distal wall 52 extends in the distal directionand extended proximal wall 96 extends in the proximal direction. In thisparticular example, the extended distal wall includes a thickened wallsection 76, including a passage 108. The passage is in effect a cavitywithin the extended distal wall, and rod end 44 is placed in thiscavity.

FIG. 29 shows a first swaging operation carried out on the extendeddistal wall—resulting in the creation of first swaged interface 98. Atthis point coupler 94 is connected to rod end 44—but the coupler is notconnected to the anchor. FIG. 30 shows the result of a second swagingoperation in which extended proximal wall 96 is swaged inward over theproximal end of the anchor to create second swaged interface 100. Theresult of the two swaging operations is that rod end 44, coupler 94,anchor 40, and cable 38 are all connected together so that a ensile loadcan be transmitted through the assembly.

FIGS. 31-32 show an additional embodiment in which swaging is used toconnect a rod end to a coupler but a threaded interface is used toconnect the coupler to the anchor. In FIG. 31 , the reader will notethat anchor 40 includes a male thread 102 on its distal end. Coupler 106includes a female thread 104 sized to engage male thread 102 and therebyattach coupler 106 to anchor 40. As for the prior example, coupler 106includes a passage 108 sized to receive rod end 44. A swaging operationis performed on the extended distal wall 52 of the coupler—as shown inFIG. 32 —thereby creating swaged interface 58. The result is that rodend 44 is connected to coupler 106, coupler 106 is connected to anchor40, and anchor 40 is connected to cable 38.

Each of the rod segments illustrated has a first rod end and a secondrod end. The rod end 44 in each of the illustrations has been the firstrod end of a rod segment. The second rod end of each such rod segment isprovided with a standard end feature—meaning an end feature configuredto interface with known connection methods. FIGS. 33 and 34 provide anon-exhaustive listing of these standard end features.

FIG. 33A depicts an anchor that is swaged to a rod segment 42. The firstrod end 44 of the rod segment 42 shown is swaged into the anchor'sextended distal wall to form swaged interface 58. The second rod end ofthe rod segment is provided with a standard end feature—in this casemale thread 108. Male thread 108 can be used to connect the rod segmentto a nipple on a bicycle wheel rim or to any other structure having asuitable female thread.

FIG. 33B depicts a rod segment 42 having a male thread 108 along itsentire length—including both rod ends. The thread on rod end 44 providesa grip-enhancing interface for the swaging operation, whereas the threadon the opposite end provides a standard end feature that is useful forconnections. FIG. 33C depicts a rod segment 42 having a loading eye 110on its second rod end. FIG. 33D depicts a rod segment having a crosspiece 112 on its second rod end. FIG. 33E depicts a rod segment having aJ-bend 12 and an expanded head 14 on its second rod end. All thesestructures are standard end features that can be used to attach the rodsegment to other structures.

FIG. 34 shows still more exemplary standard end features. FIG. 34Adepicts a rod segment having tapered end 114 on its second rod end. FIG.34B depicts a rod segment having an expanded head 14 on its second rodend. FIG. 34C depicts a rod segment having a yoke and removabletransverse pin 118 on its second rod end. FIG. 34D depicts a rod segmenthaving a distal cylinder 120 on its second rod end. The distal cylindercan be used for connection—such as by a swaging operation connecting thedistal cylinder to an external structure.

FIG. 35 depicts several different kinds of swages. FIG. 35A depicts ananchor 40 with its extended distal wall swaged to rod end 44. A sectionview “callout” is provided through swaged interface 58. The views inFIGS. 35B-35F depict cross sections corresponding to this callout.

FIG. 35B shows a circular swage 122 of the extended distal wall over rodend 44. FIG. 35C shows a square swage 124 over rod end 44. FIG. 35Dshows an octagonal swage 126 over rod end 44. FIG. 35E shows a cruciformswage 128 over rod end 44. Finally, FIG. 35F shows a convoluted swage130 over rod end 44. Differing swaging dies can be used to create allthese swaged cross sections (and many more).

In the preceding examples the swaging operation forced part of theanchor against part of a rod segment. It is also possible to use aseparate swaging die in the place of the rod segment. FIGS. 36-38illustrate this approach. In FIG. 36 a male swaging die is inserted intocavity 54 on the distal end of anchor 40. FIG. 37 shows extended distalwall 52 after it has been swaged to swaging die 132 and after theswaging die has been removed by pulling it in the distal direction.Female thread 134 has also been added to the swaged interior profile ofextended distal wall 52—typically by using a threading die. In FIG. 38 ,a rod end 44 having a male thread 108 is threaded into female thread 134in the distal end of the anchor. Rod end 44 is thereby secured to anchor40. Swaging is thus (in this example) part of the process for connectingrod end 44 to anchor 40. However, the swaging operation did not directlyconnect the anchor to the rod end.

In a variation on what is illustrated in FIG. 36 , it is possible toapply a swaging operation to the extended distal wall without thepresence of swaging die 132. In this variation the extended distal wallis still swaged inward—but no internal male die is used. The result is areduced-diameter entrance with a somewhat irregular perimeter. A hole isthen drilled or reamed in the reduced diameter resulting from the swage.A female thread is then cut in the hole after the drilling and/orreaming operation. Male thread 108 is then provided on rod end 44 andthe interface between threads 108,134 is used to connect the rod end.This is a useful process for adding a rod segment to a hybrid assemblyon the end that is nearest the hub.

In still other exemplary embodiments it is helpful to provide anadditional component that will become part of the actual swagedinterface. This component is generally referred to as an “insert.” FIG.39 shows a first example. As discussed previously, the diameter of rodend 44 is often much less than the diameter of the cavity insideextended distal wall 52. The significant difference in diameters meansthat the swaging operation has to deform the extended distal wall a gooddistance inward. An insert is used to “bridge” this difference indiameters. Extended distal wall 52 of anchor 40 in this example includesannular pocket 136. Insert 138 is also provided. The insert has apassage 142 sized to receive rod end 44. The insert also has aprotrusion 140 sized to fit within annular pocket 136. Rod end 44 isplaced through passage 142 and protrusion 140 is aligned with annularpocket 136. A swaging operation is then performed to deform the extendeddistal wall inward against the insert.

FIG. 40 shows the result. Extended distal wall 52 has been plasticallydeformed inward to press insert 138 against rod end 44 and create analtered swaged interface. Material selection can alter thecharacteristics of the swaged interface, and the presence of an insertallows additional flexibility. In the example of FIGS. 39 and 40 , therod end and the insert are made of steel. Anchor 40 is made of a moreductile material—such as aluminum. Passage 142 can also be provided withgrip-enhancing surface features like ribs, threads, or simply a roughsurface. These features enhance the grip between the rod end and theinsert when the swaging operation is performed.

FIG. 41 shows a second type of exemplary insert. Insert 144 againcontains a passage 142 sized to admit rod end 44. However, the exteriorof the insert is provided with male thread 146. The inward facing sideof extended distal wall 52 is provided with a female thread. Rod end 44is inserted through passage 142 in insert 144 and the insert—with therod end in tow—is threaded into female thread 146. After the insert isin position, a swaging operation is performed to deform the extendeddistal wall inward. FIG. 42 shows the result. Swaged interface 58 iscreated over the length of the insert 144 and an additional length inthe distal direction where the extended distal wall is actually deformedinward over the distal end of the insert.

FIG. 43 shows additional exemplary inserts. In FIG. 43A, insert 149 hasa tapered exterior wall. Insert 151 in FIG. 43B has a curved exteriorwall. Insert 150 in FIG. 43C has a more complex passage 142—including astraight portion and a tapered portion. Insert 152 in FIG. 43D has apassage 142 including a straight portion and a second portion with acurved side wall. Insert 154 in FIG. 43E has a passage with a straightportion and a tapered portion, as well as an exterior wall thatincorporates a taper.

FIG. 44 shows still more exemplary swaging inserts. Insert 156 in FIG.44A includes an internal thread and an external thread. Insert 158 inFIG. 44B uses a curved wall for passage 142 and a curved exterior wall.Insert 160 in FIG. 44C includes an internal passage 142 configured toreceive a rod end having an expanded head. Insert 162 in FIG. 44Dincludes a series of ribs 88 on its internal passage and a series ofannular reliefs 164 on its external wall.

Another form of swaging insert can be attached to the rod end prior toinsertion into the anchor cavity. FIG. 45 shows this. Rod end attachment166 in FIG. 45A is a steel sleeve that is pressed onto the end of rodend 44 to create in effect an expanded portion. The rod end—along withrod end attachment 166—is then swaged to the anchor. Rod end attachment168 in FIG. 45B is also pressed onto the end of rod end 44. Thisattachment includes an external thread. Press fitting is only one methodof attaching the rod end attachment to the rod. The attachment couldalso be swaged, glued, welded, threaded, or brazed in position. Rod endattachment 170 in FIG. 45C is threaded into place on the rod end. Thisattachment includes a tapered external surface. Rod end attachment 172in FIG. 45D is also threaded in place. This attachment includes aspherical outer surface.

Returning briefly to the embodiment of FIG. 5 , the reader will recallthat in many (though not all) cases anchor 40 will be attached to cable38 by the creation of potted region 48. The effect of the swagingoperation on the potted region is a design consideration. In looking atFIG. 6 , those skilled in the art will realize that if the swagingforces are applied too far in the proximal direction they may deform thewall surrounding potted region 48 and thereby possibly reduce thestrength of the potted connection. In some embodiments it is desirableto add features that guard against the unwanted deformation in thevicinity of the potted region.

FIG. 46 shows anchor with an additional transverse bulkhead 178 addedproximate the distal side of potted region 48. Bulkhead 178 in thisexample includes a vent 180. Additional vents may be provided—includingvents through extended distal wall 52—in order to allow the escape ofair trapped during the swaging or potting processes. Rod end attachment176 is provided on rod end 44. The rod end and its attachment are thenplaced inside cavity 54. A swaging operation is then performed todeflect extended distal wall 52 inward. FIG. 47 shows the result. Swagedinterface 58 is limited to the region distal to bulkhead 178. Thepresence of the bulkhead limits any unwanted compression on the pottedregion.

Of course, bulkhead 178 may not be provided solely to protect the pottedregion. The presence of the bulkhead also tends to modify the shape ofthe resulting swage interface, since little inward compression ispossible in the vicinity of the bulkhead. In the example of FIG. 47 ,the bulkhead has assisted in the creation of a conical shape for theswaged interface. The bulkhead may be added for other reasons aswell—such as aiding in the manufacturing process for the anchor.

FIGS. 48 and 49 illustrate a scenario where the rod segment is not aunified rigid rod. The rod segment in this version is actually a lengthof wire rope 182 with an expanded end fitting 184. The swaging operationfor connecting this rod segment to anchor 40 is the same as for priorexamples. End fitting 184 is placed inside extended distal wall 52. Theextended distal wall is swaged inward to create the swaged interface 58shown in FIG. 49 . The many other variations illustrated previously canalso be used to create a swaged connection to a rod segment containing alength of wire rope.

In fact, many of the prior exemplary features can be combined to produceadditional embodiments within the scope of the present invention. FIG.50 shows one such embodiment. In this version the anchor is split intotwo pieces—anchor 40 and coupler 186. A threaded interface 102,104 isused to join the coupler to the anchor. The coupler is provided with atransverse bulkhead 178. Rod end 44 is provided with an expanded portion62, which is helpful in creating a tapered swaged interface as shown.Many, many other combinations of previously described features arepossible.

Of course, all the rod segments have been shown being added to one endof a synthetic cable. In some applications a rod segment may in factonly be added to one end of a synthetic cable. However—in mostapplications—a rod segment will be added to both of the cable's ends.This allows the resulting assembly to be connected between two otherexternal structures and secured and tightened using the standard endfeatures incorporated in the two rod segments.

The combination of a synthetic tensile member with the two rod segments(one on each end) provides advantageous features. One example of anadvantageous feature occurs when the assembly is used as a bicyclespoke. The hybrid assembly as contemplated by the present invention canbe substituted for each spoke in a prior art bicycle wheel assembly. Theresulting assembly has different mechanical characteristics.

FIG. 51 shows a stress versus strain diagram that will be familiar tothose skilled in the art. Steel stress-strain-curve 188 shows the regionof plastic elongation for a conventional steel spoke. Stress isproportional to strain. The relationship remains the same whetherloading or unloading. The relationship is different, however, for acable made of many types of synthetic filaments. Loading curves 190,192show the stress-strain relationship for a cable made of syntheticfilaments exhibiting viscoelastic properties. Synthetic loading curve190 shows the stress-strain relationship during a phase in which load isbeing increased on the synthetic cable. Synthetic unloading curve 192shows the stress-strain relationship when the load is being decreased onthe cable. The displacement between the two curves is a result ofviscoelasticity producing a hysteresis phenomenon. Heat is lost during aloading/unloading cycle for a viscoelastic material. Thus, the syntheticmaterials absorb energy during the loading cycle and shed some of thisenergy as heat. When such materials are used as bicycle spokes, thespokes are able to absorb some of the impact energy imparted to thewheel when traveling over bumps. The result is a noticeably smootherride.

Many other advantages result from assemblies made according to thepresent invention. No attempt is made to enumerate this list ofadvantages. In addition—although an order of operations has been setforth in some of the examples given—the claims that follow should not beviewed as requiring any particular order of operations unless the claimlanguage itself so requires.

Although the preceding description contains significant detail, itshould not be construed as limiting the scope of the invention butrather as providing illustrations of the preferred embodiments of theinvention. Those skilled in the art will be able to devise many otherembodiments that carry out the present invention. Thus, the languageused in the claims shall define the invention rather than the specificembodiments provided.

Having described my invention, I claim:
 1. A method for creating ahybrid assembly of a rod segment and a flexible synthetic tensilemember, comprising: (a) providing a rod segment having a first rod endand a second rod end, with said second rod end including a standard endfeature; (b) providing said synthetic tensile member made of a pluralityof individual filaments, said synthetic tensile member having asynthetic tensile member end; (c) providing an anchor, including, (i)proximal region, (ii) a distal region, (iii) a potting cavity proximatesaid proximal region, wherein said potting cavity expands in a distaldirection, (iv) an extended distal wall, (v) a cavity enclosed by saidextended distal wall, said cavity proximate said distal region; (d)placing a length of said filaments of said synthetic tensile memberproximate said synthetic tensile member end into said potting cavity;(e) infusing said length of filaments with a liquid potting compound;(f) maintaining said length of filaments within said potting compoundwithin said potting cavity until said liquid potting compoundtransitions to a solid, thereby creating a solidified potted regionwithin said anchor; (g) placing said first rod end within said cavityenclosed by said extended distal wall and distal to said solidifiedpotted region; and (h) swaging said extended distal wall inward againstsaid first rod end in order to connect said anchor to said rod segment.2. The method for creating a hybrid assembly of a rod segment and aflexible synthetic tensile member as recited in claim 1, wherein saidfirst rod end has a grip enhancing feature.
 3. The method for creating ahybrid assembly of a rod segment and a flexible synthetic tensile memberas recited in claim 2, wherein said grip enhancing feature is selectedfrom the group consisting of an expanded portion, a thread, a taperedexpansion, a pointed rib, a square rib, a conical end portion, anexpanded head, and a helical groove.
 4. The method for creating a hybridassembly of a rod segment and a flexible synthetic tensile member asrecited in claim 1, wherein an inward facing side of said extendeddistal wall has a grip enhancing feature.
 5. The method for creating ahybrid assembly of a rod segment and a flexible synthetic tensile memberas recited in claim 4, wherein said grip enhancing feature is selectedfrom the group consisting of a thickened wall section, a neck portion, arib, and a thread.
 6. The method for creating a hybrid assembly of a rodsegment and a flexible synthetic tensile member as recited in claim 1,further comprising: (a) wherein said synthetic tensile member has asecond synthetic tensile member end; (b) providing a second rod segmenthaving a third rod end and a fourth rod end, with said fourth rod endincluding a standard end feature; (c) providing a second anchor,including a second extended distal wall and a second cavity enclosed bysaid second distal wall; (d) connecting said second anchor to saidsecond synthetic tensile member end of said synthetic tensile member;(e) placing said third rod end within said second cavity; and (f)swaging said second extended distal wall inward against said third rodend in order to connect said second anchor to said second rod segment.7. The method for creating a hybrid assembly of a rod segment and aflexible synthetic tensile member as recited in claim 1, wherein saidswaging step is carried out in a first stage and a second stage.
 8. Themethod for creating a hybrid assembly of a rod segment and a flexiblesynthetic tensile member as recited in claim 1, wherein: (a) said anchorincludes a removable coupler; and (b) said extended distal wall and saidcavity enclosed by said extended distal wall are located on saidcoupler.
 9. The method for creating a hybrid assembly of a rod segmentand a flexible synthetic tensile member as recited in claim 8, furthercomprising a transverse bulkhead in said coupler.
 10. The method forcreating a hybrid assembly of a rod segment and a flexible synthetictensile member as recited in claim 1, wherein said swaging produces aswaged interface having a cross section selected from the groupconsisting of circular, square, octagonal, cruciform, and convoluted.11. The method for creating a hybrid assembly of a rod segment and aflexible synthetic tensile member as recited in claim 1, furthercomprising: (a) providing an insert on said rod end; and (b) whereinsaid swaging step swages said extended distal wall inward against saidinsert.
 12. The method for creating a hybrid assembly of a rod segmentand a flexible synthetic tensile member as recited in claim 1, furthercomprising: (a) providing a rod end attachment on said first rod end;and (b) wherein said swaging step swages said extended distal wallinward against said rod end attachment on said first rod end.
 13. Themethod for creating a hybrid assembly of a rod segment and a flexiblesynthetic tensile member as recited in claim 1, wherein said anchorincludes a transverse bulkhead proximate said cavity.
 14. A method forcreating a hybrid assembly of a rod segment and a flexible synthetictensile member, comprising: (a) providing a rod segment having a firstrod end and a second rod end, with said second rod end including astandard end feature; (b) providing said synthetic tensile member madeof a plurality of individual filaments, said synthetic tensile memberhaving a synthetic tensile member end; (c) providing an anchor,including an extended distal wall, an expanding potting cavity, and acavity that is distal to said expanding potting cavity; (d) connectingsaid anchor to said synthetic tensile member end of said synthetictensile member by potting a length of said plurality of individualfilaments into said expanding potting cavity, thereby creating asolidified potted region within said anchor; (e) placing said first rodend within said cavity and distal to said solidified potted region; and(f) swaging said extended distal wall inward against said first rod endin order to connect said anchor to said rod segment.
 15. The method forcreating a hybrid assembly of a rod segment and a flexible synthetictensile member as recited in claim 14, wherein said first rod end has agrip enhancing feature.
 16. The method for creating a hybrid assembly ofa rod segment and a flexible synthetic tensile member as recited inclaim 15, wherein said grip enhancing feature is selected from the groupconsisting of an expanded portion, a thread, a tapered expansion, apointed rib, a square rib, a conical end portion, an expanded head, anda helical groove.
 17. The method for creating a hybrid assembly of a rodsegment and a flexible synthetic tensile member as recited in claim 14,wherein an inward facing side of said extended distal wall has a gripenhancing feature.
 18. The method for creating a hybrid assembly of arod segment and a flexible synthetic tensile member as recited in claim17, wherein said grip enhancing feature is selected from the groupconsisting of a thickened wall section, a neck portion, a rib, and athread.
 19. The method for creating a hybrid assembly of a rod segmentand a flexible synthetic tensile member as recited in claim 14, furthercomprising: (a) wherein said synthetic tensile member has a secondsynthetic tensile member end; (b) providing a second rod segment havinga third rod end and a fourth rod end, with said fourth rod end includinga standard end feature; (c) providing a second anchor, including asecond extended distal wall and a second cavity enclosed by said seconddistal wall; (d) connecting said second anchor to said second synthetictensile member end of said synthetic tensile member; (e) placing saidthird rod end within said second cavity; and (f) swaging said secondextended distal wall inward against said third rod end in order toconnect said second anchor to said second rod segment.
 20. The methodfor creating a hybrid assembly of a rod segment and a flexible synthetictensile member as recited in claim 14, wherein said swaging step iscarried out in a first stage and a second stage.
 21. The method forcreating a hybrid assembly of a rod segment and a flexible synthetictensile member as recited in claim 14, wherein: (a) said anchor includesa removable coupler; and (b) said extended distal wall and said cavityenclosed by said extended distal wall are located on said coupler. 22.The method for creating a hybrid assembly of a rod segment and aflexible synthetic tensile member as recited in claim 21, furthercomprising a transverse bulkhead in said coupler.
 23. The method forcreating a hybrid assembly of a rod segment and a flexible synthetictensile member as recited in claim 14, wherein said swaging produces aswaged interface having a cross section selected from the groupconsisting of circular, square, octagonal, cruciform, and convoluted.24. The method for creating a hybrid assembly of a rod segment and aflexible synthetic tensile member as recited in claim 14, furthercomprising: (a) providing an insert on said rod end; and (b) whereinsaid swaging step swages said extended distal wall inward against saidinsert.
 25. The method for creating a hybrid assembly of a rod segmentand a flexible synthetic tensile member as recited in claim 14, furthercomprising: (a) providing a rod end attachment on said first rod end;and (b) wherein said swaging step swages said extended distal wallinward against said rod end attachment on said first rod end.
 26. Themethod for creating a hybrid assembly of a rod segment and a flexiblesynthetic tensile member as recited in claim 14, wherein said anchorincludes a transverse bulkhead proximate said cavity.